scaffold-clamp-common.scad

   1 // -*- C -*-
   2
   3 include <utils.scad>
   4
   5 tube_dia = 48.3;
   6
   7 th = 7;
   8
   9 pin_gap = 1.5; // around
  10
  11 smooth_r = 15;
  12
  13 bolt_dia = 5 + 0.75;
  14 bolt_flat = 10 + 1;
  15
  16 open_gap = 10;
  17
  18 hinge_unit = 10;
  19 hinge_z_gap = 1;
  20
  21 hinge_units = 4;
  22
  23 // ---------- vhook ----------
  24
  25 vhook_th = 14;
  26
  27 // ---------- hhook ----------
  28
  29 hhook_inside = 40;
  30 hhook_th = 4;
  31 hhook_l = 40;
  32
  33 // ========== calculated ==========
  34
  35 pin_dia = th;
  36 hole_dia = th + pin_gap;
  37
  38 main_r = tube_dia/2 + th;
  39
  40 hinge_gap = pin_gap;
  41
  42 hinge_o_r = 0.5 * hole_dia + th;
  43
  44 hinge_x = -0.5 * tube_dia - hinge_o_r;
  45 bolt_x = 0.5 * tube_dia + th + bolt_flat * 0.5;
  46 max_x = bolt_x + max(0.5 + bolt_dia + th, 0.5 * bolt_flat/2);
  47
  48 flats_y = open_gap/2 + th;
  49
  50 stride_z = hinge_unit*2 + hinge_z_gap*2;
  51 total_z = hinge_units * stride_z - hinge_z_gap;
  52
  53 min_z = -total_z/2;
  54 max_z = +total_z/2;
  55
  56 pin_flatten = pin_dia/2 * (1 - cos(45));
  57
  58 // calculated - vhook
  59
  60 vhook_inside = 15;
  61
  62 vhook_theta = atan2( smooth_r, main_r );
  63
  64 vhook_y0 = -max(main_r, (tube_dia/2 + vhook_th));
  65 vhook_ctr = vhook_y0 - vhook_inside/2;
  66 vhook_outer_dia = vhook_inside + vhook_th*2;
  67
  68 // calculated - hhook
  69
  70 hhook_outer_dia = hhook_inside + hhook_th*2;
  71
  72 hhook_ctr = -max(main_r + hhook_inside/2,
  73                  tube_dia/2 + hhook_outer_dia/2);
  74
  75 $fa = 3;
  76 $fs = 0.1;
  77
  78 module SmoothPlan(){
  79   offset(r=-smooth_r) offset(delta=smooth_r) children(0);
  80 }
  81
  82 module TubePlan(){ circle(r = tube_dia/2); }
  83 module MainCirclePlan(){ circle(r = main_r); }
  84
  85 module PlanWeldMainCircle(){
  86   intersection(){
  87     difference(){
  88       SmoothPlan(){
  89         union(){
  90           MainCirclePlan();
  91           children(0);
  92         }
  93       }
  94       TubePlan();
  95     }
  96     rotate(-135) square(100);
  97   }
  98 }
  99
 100 module MainPlan(flatten=false) {
 101   difference(){
 102     SmoothPlan()
 103       union(){
 104       translate([hinge_x, 0]) circle(r= hinge_o_r);
 105       MainCirclePlan();
 106       rectfromto([0,           -flats_y],
 107                  [max_x,       +flats_y]);
 108     }
 109     TubePlan();
 110     rectfromto([0,       -open_gap/2],
 111                [max_x+1, +open_gap/2]);
 112     translate([hinge_x, 0]) {
 113       intersection(){
 114         circle(r= hole_dia/2);
 115         if (flatten)
 116           translate([ pin_flatten, 0 ])
 117           square(center=true, [hole_dia, hole_dia + 1]);
 118       }
 119     }
 120   }
 121 }
 122
 123 module Portion(d=0) {
 124   translate([hinge_x, 0]) circle(r= hinge_o_r + d);
 125   rectfromto([hinge_x*2, 0],
 126              [max_x+10, -(tube_dia/2+th+10)]);
 127 }
 128
 129 module MainPlanA(flatten){
 130   intersection(){
 131     MainPlan(flatten);
 132     Portion(0);
 133   }
 134 }
 135
 136 module MainPlanB(flatten){
 137   difference(){
 138     MainPlan(flatten);
 139     Portion(hinge_gap);
 140   }
 141 }
 142
 143 module HalfClampX(flatten=false){
 144   difference(){
 145     translate([0,0, min_z]) {
 146       linextr(0, total_z) mirror([0,1]) MainPlanB();
 147       for (i=[0 : hinge_units-1]) {
 148         translate([0,0, stride_z*i])
 149           linextr(0, hinge_unit) MainPlanA(flatten);
 150       }
 151     }
 152     for (dz=[-1,+1]) {
 153       translate([ bolt_x, 0, dz * total_z/4 ]) {
 154         translate([0, -tube_dia/2, 0])
 155           rotate([-90,0,0])
 156           cylinder(r= bolt_dia/2, h= tube_dia);
 157         translate([0, -flats_y, 0])
 158           rotate([90,0,0])
 159           cylinder(r= bolt_flat/2, h= tube_dia/2);
 160       }
 161     }
 162   }
 163 }
 164
 165 // ---------- vhook ----------
 166
 167 module VHookProfile() {
 168   translate([0, -vhook_inside/2 - vhook_th/2])
 169     circle(r = vhook_th/2);
 170 }
 171
 172 module VHookHookMain(outer=false){ ////toplevel
 173   rotate([0,90,0])
 174     rotate_extrude(convexity=10)
 175     rotate([0,0,90])
 176     hull(){
 177       VHookProfile();
 178       if (outer) {
 179         translate([0,-vhook_outer_dia]) square(center=true, vhook_th);
 180       }
 181     }
 182 }
 183
 184 module VHookPartA(){ ////toplevel
 185   DummyA();
 186
 187   translate([0, vhook_ctr, 0]){
 188     for (m=[0,1]) {
 189       mirror([0, m, 0]) {
 190         linextr(-0.1, vhook_outer_dia/2)
 191           VHookProfile();
 192         translate([0, -vhook_inside/2 -vhook_th/2, vhook_outer_dia/2])
 193           sphere(r= vhook_th/2);
 194       }
 195     }
 196
 197     intersection(){
 198       VHookHookMain(outer=true);
 199       linextr_y_xz(0, vhook_outer_dia/2) hull(){
 200         VHookProfile();
 201         translate([0,-0.1]) square(center=true, [vhook_th, 0.2]);
 202       }
 203     }
 204
 205     intersection(){
 206       VHookHookMain();
 207       translate([0,0, -vhook_outer_dia])
 208         cube(center=true, vhook_outer_dia*2);
 209     }
 210   }
 211
 212   //translate([0, vhook_y0, 50]) rotate([0,0,-90]) color("black") cube(10);
 213   // translate([0,0,-150]) rotate([0,0,180 + theta]) color("blue") cube(100);
 214 }
 215
 216 module VHookPlanDemo(){
 217   MainPlanA();
 218   translate([0, vhook_ctr, 5])
 219     for (m=[0,1]) {
 220       mirror([0,m])
 221         color("blue") VHookProfile();
 222     }
 223 }
 224
 225 // ---------- hhook ----------
 226
 227 module HHookHookPlan(){
 228   translate([0, hhook_ctr]){
 229     difference(){
 230       circle(r = hhook_outer_dia/2);
 231       circle(r = hhook_inside/2);
 232       rectfromto([-hhook_outer_dia, -hhook_outer_dia],
 233                  [0,                +hhook_outer_dia]);
 234     }
 235     translate([0, -(hhook_inside/2 + hhook_th/2)]){
 236       hull(){
 237         for (x=[0.1, -hhook_l]) {
 238           translate([x,0]) square(center=true, hhook_th);
 239         }
 240       }
 241     }
 242   }
 243 }
 244
 245 module HHookPlanDemo(){
 246   MainPlanA();
 247   HHookHookPlan();
 248 }
 249
 250 // ---------- misc ----------
 251
 252 module GeneralB(){ ////toplevel
 253   HalfClampX(true);
 254 }
 255
 256 module DummyA(){ ////toplevel
 257   HalfClampX();
 258 }
 259
 260 module PlanDemo(){ ////toplevel
 261   MainPlan();
 262   translate([0,0,-4]) color("red") Portion(1);
 263   translate([0,0,-2]) color("grey") Portion(0);
 264
 265   translate([0, tube_dia*1.5]) {
 266     MainPlanB();
 267     MainPlanA();
 268   }
 269
 270   translate([0, -tube_dia*1.5]) {
 271     VHookPlanDemo();
 272   }
 273   translate([tube_dia*4, 0]) {
 274     HHookPlanDemo();
 275   }
 276 //  translate([max_x - hinge_x + 20, 0]) color("blue") MainPlanA();
 277 }
 278
 279 module Demo(){ ////toplevel
 280   color("red") rotate([180,0,0]) GeneralB();
 281   color("blue") DummyA();
 282 }
 283
 284 //PlanDemo();
 285 //HalfClamp();